Checking the steam network at a carbonated beverage production facility revealed that the steam condensate is not recovered, leading to loss of water and energy. Installing a condensate recovery network is a feasible alternative to conserve natural resources.
The pasteurization temperature within a juice manufacturing company was allowed to exceed the set limit. Maintaining the pasteurization temperature at the defined set point shall save on energy use.
A carbonated drinks facility used diesel fuel to operate its boiler despite it was connected to the natural gas grid. Replacing the boiler’s burner with one that can fire natural gas, and increasing the contracted capacity for natural gas was found as a feasible measure to maintain economic benefits and reduce the pollution load.
Due to its obselete design, the boiler de-aerator of a beverage company was not functioning properly leading to over consumption of energy in the boiler, and increase corrosion within the steam network. Changing the de-aerator with an updated design shall allow complete removal of air and incondesible gases from the condensate, saving on energy consumption
A beverage and juice manufacturing company had an oversized, obselete design compressor running at low load factor. This caused excess energy consumption. Replacing the compressor from a piston type compressor to a smaller size rotary-screw type compressor shall increase the efficiency of the compressor, and reduce the unload time which is a waste of energy.
Lack of maintenance in a carbonated beverage production facility resulted in production interuptions, as well as deterioration in product quality resulting from poor performance of utilities. Adopting a preventive maintenance program associated with periodic measurment of main parameters eliminate those losses.
A beverage company practiced overcleaning within their CIP program, which was based on 7-step CIP. Common practice for simillar industry is to use only 5-step CIP, provided that the nature of the production, the temperature and concentration of the solutions, the laboratory controls and the preventative measures are taken into consideration.
Changing to 5-step CIP reduced the chemicals used by the company, water and energy needed for a non-productive process.
Air compressors are known to account for a big portion of electricity consumption, especially when they are poorly controlled. In a company operating with three high pressure compressors in parallel, only two of which were connected through a sequencer to optimize their load/unload patterns. The third compressor was operating without the sequencer, and had frequent starts. Connecting the third compressor to the sequencer shall harmonize the operation of the three compressors, and save on energy consumption.
Market returns for a juice company is high, leading to loss of final products as the company practiced disposal of those returns. Following a laboratory assessment, around 70% of the market returns that can be reprocessed while satisfying the health and hygiene standards.
Detailed analysis for the product loss in a PET hot filling machine revealed that the cause of the loss was associated with the quality of used performs, leading to expansion of the bottles, and overfilling with product.